Corrugated Wood Board Shaping and Stabilization System
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Solution Overview
Problem
Existing methods for manufacturing corrugated boards struggle to maintain a corrugated shape without using additional materials like adhesives, which compromises the natural texture and aroma of wood, especially in humid environments.
Innovation Solution
A system comprising a rotary cutting apparatus, corrugated-shape processing apparatus, shaping apparatus, stabilizing apparatus, and bonding apparatus that processes and stabilizes a single wood plate into a corrugated shape using heat and cooling jigs, and bonds it to a flat plate with adhesive only on protrusions, preserving the wood's natural properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a board is processed in a corrugated shape without coating or adhesive, then the natural texture and aroma of the board are preserved, but the flexural portion becomes loosened and the board gradually restores to its original straight shape, especially in humid environments
Solution Approach 1:
The patent applies preliminary action by treating the board with a fixing agent before the corrugated shape fully sets, preventing the wood fibers from returning to their original state. This preliminary treatment locks in the corrugated structure before moisture or humidity can cause restoration to the straight shape.
Solution Approach 2:
The patent changes physical parameters by controlling moisture content, temperature, and applying fixing agents during the corrugation process. These parameter changes modify the wood fiber properties to maintain the corrugated shape without requiring full adhesive coating, thus preserving natural texture while preventing shape restoration.
2Stability of the object's composition
If adhesive is applied to maintain the corrugated state, then the shape stability is improved even in humid environments, but the natural texture and aroma of the board are compromised and synthetic materials must be used
Solution Approach 1:
The patent applies local quality by using minimal adhesive only at critical locations where shape maintenance is most needed, rather than coating the entire surface. This localized application preserves the natural texture and aroma of the board while still providing sufficient structural support to maintain the corrugated shape.
Solution Approach 2:
The patent employs a minimal amount of adhesive as a temporary or localized support rather than a permanent full-surface coating. This approach uses the adhesive only where absolutely necessary to prevent shape restoration, allowing the natural wood properties to remain dominant and preservable.
3Stability of the object's composition
If plywood or separate boards attached with adhesive are used, then the corrugated state is maintained without returning to board shape in humid conditions, but additional materials beyond natural wood are required
Solution Approach 1:
The patent extracts or removes the need for extensive adhesive usage and complex multi-layer plywood structures. Instead, it uses a simplified approach with minimal adhesive application combined with physical corrugation and fixing agent treatment, thereby maintaining shape stability while preserving the versatility and natural properties of single-piece wood.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively maintains the corrugated shape of the wood board without using external adhesives, allowing the natural texture and aroma of the wood to be utilized while providing stability against shape restoration due to moisture, resulting in a durable and aesthetically pleasing product.
Implementation Method 1
a board is fed between two heat rollers each provided in its outer periphery with asperities to be pressed and curved by the two heat rollers
Implementation Method 2
for processing a board in a corrugated shape
Implementation Method 3
stabilizing apparatus for stabilizing the corrugated board shaped in the corrugated shape
Data Source
Figure 1
Figure 2
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AI summary
There is provided a system 1 of manufacturing a corrugated board, including: a corrugated-shape processing apparatus 4 for processing a board in a corrugated shape by curving the board; a shaping apparatus 5 for adjusting a corrugated board acquired by processing the board in a corrugated shape; and a stabilizing apparatus 6 for stabilizing the corrugated board being shaped in the corrugated shape, the corrugated-shape processing apparatus 4 including a first pressing jig 25 and a second pressing jig 27 each of which is in a roller-like shape provided on its surface with asperities to press a board into a corrugated board, being disposed facing each other, the shaping apparatus 5 including: a third pressing jig 45 and a fourth pressing jig 48 each of which has a surface with asperities in which a distance between adjacent apexes of the asperities is substantially identical to that of a surface with asperities of the corrugated board; and a heater 59, the stabilizing apparatus 6 including a fifth pressing jig 65 and a sixth pressing jig 68 each of which has a surface with asperities in which a distance between adjacent apexes of the asperities is substantially identical to that of a surface with asperities of the corrugated board after the heat-press process; and a cooling unit 69. As a result, a single board can be processed in a corrugated shape and a state of the corrugated shape can be maintained.